Electric switch



March 25, 1941. G J. MEUER 2,236,343

ELECTRIC SWITCH Filed April 26, 1937 5 Sheets-Sheet 1 a a I 29 29 a 30 c 50 50 a C a9 za a March 25;, E410 a. J. MEUEER 2 3 33 ELECTRIC SWITCH Filed April 26, 193? 3 Shasta-$l1eeiz 5 Patented Mar. 25, 1941 2.236.343 ELECTRIC swrron George J. Meuer, Milwaukee, Wis, assignor to Cutler-Hammer, Inc., Milwaukee,

ration of Delaware Wia, a corpo- Application April 26, 1937, Serial No. 138,912

9 Claims.

This invention relates to improvements in electric switches. The invention relates more particularly'tc snap switches adapted for use in con junction with radio rheostats and the line.

An object of the invention is to improve and simplify the details of construction, arrangement and operation of switches of the aforementioned character.

Another object is to provide for reduction in over-all dimensions of such a switch of given current controlling capacity.

Another object is to provide a novel form and arrangement or the stationary and movable contact elements of the switch.

Another object is to minimize the number of different parts required for production of switches having various difierent control characteristics.

Another object is to provide a novel form of switch base and a novel form of mounting means therefor.

Another object is to provide a novel form of insulating carrier adapted to alternatively accommodate one ormore bridging contactors for the switch, according to the circuit controlling arrangement desired.

Another object is to provide a substantially dust-tight switch of the character aforementioned.

Other objects andv advantages of the invention will hereinafter appear.

The accompanying drawings illustrate various embodiments of the invention which will now be described; it being understood that the embodiments illustrated are susceptible of modification in respect of certain details of construction thereof withoutdeparting from the scope of the appended claims.

In the drawings,

Figure 1 is a top plan view (double-scale) of a single pole single throw snap switch constructed in accordance with my invention. 7

Fig. 2 is a sectional view, on the line 2-2 of Fig. 1, but showing the .same mounted in a metal casing in conjunction with aradio rheostat.

' tactor in bridging relation to the stationary con- (Cl. Wit-48) tact-s of the switch, and showing the manner of rigidly attaching the lower contact to the base.

Fig. 'l is a view similar to Fig. l, but showing added parts to provide a switch of the double pole single throw type.

Fig. 8 is a sectional view, on the broken line Fig. 9 is a bottom plan view of a switch having a slightly modified form of base to accommodate a bus member for electrically connecting two of the stationary contacts of the switch.

Fig. i0 is a sectional view, on the broken line it-ld of Fig. 9, showing the arrangement of a pair of bridging contactors to provide a threeway switch.

Fig. 11 is a fragmentary top plan view of a base haviw parts arranged to provide a switch of the so-called four-wire type, in which a common electrical connection is provided for the four wiring terminals in the on position of the switch. 0

Fig. 12 is a sectional view, on the broken line of Fig. 11, illustrating the bus member providing an electrical connection between the bridging contactors of the switch.

9 Fig. 13 is a perspective view of a modified form of combined contact and terminal member, which is stamped from a bimetallic punching.

Fig. 1a is a plan view of the flat, punched insulating plate or carrier.

Fig. 15 is an enlarged fragmentary sectional view, similar to Fig. 6, but showing a modified form of combined contact and terminal member and the manner of attaching the same to the base, and

Figs. 16 to 20 are views of a switch having a modified form of actuating member, and a modified form of supporting and operating means for the switch as a whole.

Referring first to Figs. 1 to 6, the numeral 25 designates the switch base, which is molded from a. suitable insulating material, such as the phenol formaldehyde condensation product sold com mercially under the trade name of Bakelite. Base 25, which is preferably of substantially circular contour is provided with a substantially cylindrical recess 26 opening to the upper surface thereof. As best illustrated in Fig. 4, recess 26 is provided on its bottom wall with a projection or boss 21 forming a substantially triangular bearing ledge for the fiat punched insulating plate 28 which serves as the contactor carrier of the switch. Superimposed upon plate 28 is a punched and stamped sheet metal actuator 29, the main body portion of which is of substantially diamond-shape.

An opening 21 peneall trates the projection 2! to accommodate the shank of a pivot post 30; and plate 28 and actuator 29 are respectively provided with openings 28 and 29*- (Figs. 2 and 14) which register with each other to accommodate the enlarged portion 30 of said post. Pivot post 3i! is provided with a head 36 to prevent upward displacement of parts 28 and 29, and the shank of post 39 is upset over the bottom surface of base 25, as shown at 36, to secure said parts in assembled relation.

The peripheral wall of recess 26 is provided with a pair of ribs or inward projections 3i and 32 which are adapted for engagement alternately by the angularly arranged edges of the main body portion of actuator 29, to limit the oscillatory movements of the latter. ,The provision of ribs 3| and 32 minimizes the required width or dimensions of the metal blank from which actuator 29 is formed. Actuator 29 is provided as shown with a pair of sheared and upwardly struck arms 29 29 arranged at a. predetermined angle relatively to each other to provide for transient engagement thereof alternately by an operating member of suitable form. Such an operating member is shown at 38 in Fig. 2, the same comprising asheet metal member of substantially U-shape in horizontal cross section; member 33 being rigidly attached to shaft at, in an eccentric relation, for rotation with the latter.

As illustrated in Fig. 4, the bottom wall of recess 26 is provided with two sets of sub-recesses 35, 36, 31 and 38, 39, M which are preferably initially provided with relatively thin diaphragms integral with the side walls thereof. When a single pole double throw switch having normal operation (as shown in Fig. 1) is to be produced, the diaphragms of the set of recesses 38, 39, 80 are broached out or removed, the diaphragms of the set of recesses 35, .88, 31 being permitted to remain intact. A one-piece combined contact and wiring terminal member A! has the reduced upper end di inserted upwardly through the opening provided by removal of the diaphragm from sub-recess (iii, and the projecting portions of said upper end di as shown at Al ti in Fig. 6, are upset over the bottom wall of recess 26, asshown in full lines in this figure. As shown in Fig. 6, member Al is provided with shoulders engaging the lower surface of base 25, whereby the upper or contact edge di of member fill is positioned substantially flush with, or even slightly below, the bottom wall of recess 26. The depending lower end di of member M is provided with an opening to facilitate attachment of a terminal wire -(not shown). Also as shown in Figs. 4 and 5, those portions'of recesses 81 and it adjacentto the bottom wall of recess 28 are substantially wider than the stationary contact portions to. be positioned therein, to insure engagement of the respectivecontact heads 67 with said contact portions, even after the latter are considerably worn, and to minimize deposition of metal particles upon the bottom wall of said recess.

A one-piece resilient sheet metal contact and wiring terminal member has a perforated portion 32 seated fiatwise upon the bottom wall of recess 26, a headed rivet 63 being'preferably insertable downwardly through the perforation in said portion and through the opening provided by removal of the diaphragm from sub-recess 39, and having its shank d3 upset over the lower surface of base 25 (see Fig. 3). Extending downwardly at asubstantially right angle to p rtion 42, and penetrating the opening provided by removal of the diaphragm from sub-recess 38, is a portion Q2 which is perforated as shown in Fig.- 2 to iacilitate attachment of a terminal wire. A portion 32 is bent upwardly at substantially a right angle to portion s2; and a curved arm 52 is bent to extend substantially horizontally in a plane a substantial distance below the upper surface of base 25. The free end of arm 42 is bent to extend downwardly and then upwardly (as best shown in Fig. 5) to provide a contact tip 62 whichoverlies the aforementioned contact edge Ad (Fig. 6) of member M.

The aforementioned insulating plate 28 is provided with a relatively large opening 28' intermediate the ends thereof, said opening being adapted to provide clearance for a coiled compression spring 63, one diametrically extending end portion 63 of which is inserted upwardly through a bearing opening provided in the forward end portion 29 of actuator 29, said end portion 29 being preferably bent downwardly (Fig. 2) to lie within the plane of plate 28. Seated within the forward end of spring 53 is a metal cup member 54 which is adapted to bear against an abutment 28 formed at the forward end wall of opening 28*.

Formed integrally with the bottom and peripheral walls of recess 26 are a pair of abutments' 65 and 66, against the vertical surfaces of which the plate 28 is respectively adapted to abut or. strike to limit oscillatory movements of said plate. ments 55 and 88 end in a plane substantially below the upper surface of base 25 to avoidinterference between the same and the arms of the As best illustrated in Fig. 5, abutresilient contacts, one of which is shown at 42 in this figure.

The forward. end 28 of plate 28 is preferably wider than-the main body portion thereof, and saidend is provided with an arcuate series of four openings 28, 28 28 and 28 into any one of which the reduced or shank end er of a effect bridging engagement of contactor d? with contact tip 32 and contact edge portion M As will be apparent from Fig. l, the switch is on upon snap movement of plate 28 in a clockwise direction to one of its extreme positions,

and the switch is o upon snap movement of plate 28 in a counterclockwise direction to its other extreme position, the contactor being positioned within plate opening 28. The exact reverse of this function may be obtained by omitting the contactor li from opening 28* and placing the same within plate opening 28, The reverse oi the electrical function provided by the switch of Figs. 1 to 6 may likewise be provided byomitting the contactor from plate opening 28 and placing the same in opening 28 the member ti in such an arrangement being omitted from the sub-recess it? and placed in the opening to be provided upon removal of. the diaphragm from sub-recess 37; the left-hand com through bus member 53 to' resilient contact portion 42 and tip 42* through the left-hand contactor 41, to and through the left-hand combined contact and terminal member 4!. A three-way switch having characteristics the reverse of those 'just described may be provided by simply transposing the two contactors El from plate openings 28 and 28 to plate openings 28 and 2%, respec contactors 67. Bus member as is thus positioned between the lower surface of plate 28 and the 7 heads 67 of the contactors, to provide a continuous electrical connection between the latter.

' The switchis shown in off position in Figs. 11

-fibrous material impregnated with a phenol and 12, but upon extreme clockwise positioning of plate 28 the contactors t? are engaged with their respectively cooperating pairs of stationary contacts; and inasmuch as contactors ll are electrically connected with each other, it follows that all of the four wiring terminals are electrically connected with each other in the "on position of the switch. Such a switch may be employed for control of the "A, B and (3" battery supply in a radio receiving set.

Although the bus member so in Figs. 11 and 12 is shown as comprising a straight strip which underlies the opening 23 in plate it. it will be apparent from Fig. 11 that the intermediate portion of said bus member might be onset toward the plate opening 29 to afford clearance for a third contactor to be inserted within said plate opening 28 With an arrangement like that just described, and with the other switch parts in the positions thereof shown in Figs. 11 and 12, a circuit would be completed between terminal id and the right-hand terminal 5! (Fig. 12) independently of the other switch terminals. Various other modifications and re arrangements of the switch parts will be apparent to those skilled in the art as the occasions therefor arise.

In Fig. 13 I have sho a resilient stationary contact and terminal member as which is formed from a bi-metallic punching. The lower layer th of this element preferably consists of coin silver, and the upper layer t5 thereof may consist of phosphor bronze, beryllium copper, or even ordinary pure copper. A member so constructed has the necessary resiliency, is extremely long-lived, and has a. relatively high current controlling capacity.

The aforementionedplate 28 shown in Fig. 14 is preferably punched from a laminated sheet of formaldehyde condensation product.

In the fragmentary view of Fig. 15 I have shown a one-piece combined contact and ter= minal member 68 which is insertable downwardly through an opening (such as i l) provided in the bottom wall of base recess it, said member hav-. ing-shoulders 66 66 formed at the upper end thereof for engagement with the bottom wall of recess 26. tween said shoulder portions is preferably arranged flush with the bottom wall of said rooms 26, for cooperation with a contactor 4'5 of the character aforedescribed. Member to is provided with lugs 66 and 55 (shown in dotted The upper or contact edge se belines) which are bent to the full line positions thereof against the lower surface of base 25 to rigidly and permanently secure said member to said base. g

The single pole single throw switch illustrated in Figs. 16 to 20 may be substantially like that shown in Figs. 1 to 6, and like parts have been given like numerals of reference. In this modified device, howevena special form of actuating element is provided, and the switch base is mounted in a novel manner to provide for operation thereof by means located laterally of the switch. If it be assumed that the aforedescribed base 25 is employed, the peripheral wall of the latter is ground out or otherwise removed to provide an upwardly opening notch the side walls of which are designated by the numerals 81 and $8 in Fig. 16; or a base 25 having sucha notch formed therein by the molding operation may be employed. Said notch provides clearance for the laterally extending forked end 69 of an actu-' ating member ('59, which is punched and stamped from sheet metal. Member 69 is provided with a bearing opening to" to accommodate the portion 36 of the pivot post, as shown in dotted lines in Fig. 16. The inner end 69 of member 69 is bent downwardly to lie within the plane of plate 2@, as heretofore described in connection with the other forms of switches; and said end is provided with an opening 69 to accommodate .se being bent into the corresponding recesses provided in the lower surface of base 25, as illustrated at it in Fig. 19, to restrain said parts against relative rotation. Member to is preferably provided at its upper end with three lugs W in and m which are respectively engaged with correspondingly shaped notches in a metal plate 70 (Fig. 17), said lugs being bent inwardly over plate H to rigidly secure said parts to each other. Plate it is provided with an opening li of approximately circular form, the wall of which is provided with notches. Opening l i is adapted to accommodate the reduced end it of a hollow metal bushing 172, said reduced end being upset over that surface of plate ll against which switch 1 by an upsetting operation, as shown at it in Fig.

19. Disk 18 is provided with 9. lug 73 extending inwardly therefrom into the plane'of the main body portion of member 89, whereby lug 73' is transiently engageable alternately with the respective extensions to of member 69 upon rotationof shaft id in opposite directions. Thus,

with reference to Fig. 18, wherein the switch is shown in "ofi position, it will be apparent that upon a given degree of counterclockwise rotation of shaft 8d the switch will be thrown to on position, and the shaft may be rotated farther in a counterclockwise direction pending engagement member attached thereto, with the contact element of a radio rlieostat or the like which is located at a point remotezfrom the switch 25.

Thus it may be assumed that the part 15, Figs.

18 and 19, designates an automobile dashboard.

Dashboard it is provided with an opening W to accommodate the reduced and threaded end l2 of bushing 12, said bushing being rigidly clamped to dashboard it as by means of a nut Hi. Shaft id is preferably provided with a peripheral groove M which accommodates a washer ll of horse-shoe shape, whereby inward displacement of the shaft with respect to the bushing is prevented. Fitted over the outer end of shaft id is a knob l5, preferably consisting of molded insulation, said knob having a threaded lateral opening it formed therein to accommodate a set screw 88, which when tightened is adapted to restrain the knob against rotation relatively to the shaft.

What I claim as new and desire to secure by Letters Patent is:

i. In an electric snap switch, incombination, a recessed molded insulating base, a fiat plate of insulating material pivotally supported upon the bottom wall of said base for movement in parallel spaced relation thereto from one extreme position to the other, said base and said plate having cooperating parts formed integrally therewith to limit such movement, the free-end of said plate being relatively wider than the main body portion thereof and said end being provided with four openings arranged in an arc concentric to the pivot point, a pair of contactors or" like form having enlarged hemispherical heads and cylindrical shank portions, the shank portions of said contactors being freely inserted upwardly and slidably positioned within two of said openings on opposite sides respectively of the center line of said plate, said contactors being restrained -by the walls of said openings against substantial movement transversely of said plate, a plurality of pairs of alined stationary contacts respectively positioned above and below said plate, the

contacts of said pairs being adapted for simul-' break type for radio rheostats and the like, in

combination, a. molded insulating base having a recess opening to the upper surface thereof, said recess having a relatively small substantially rectangular opening formed in the bottom wall thereof, a one-piece, fiat, punched sheet metal contact and terminal member positioned edge-- wise within said opening, said metal member having shoulders formed thereon for respectively engaging the bottom wall of said recess and the bottom surface of said base, certain of said shoulders being formed byan edgewlse upsetting operation after insertion of said member into said opening, said metal member having ,a punched upper edge forming a contact portion located in a plane substantially flush with the bottom wall of said recess, an insulating plate positioned within said recess in parallel relation to the bottom wall thereof and movable transversely with respect thereto, a contactor loosely carried by said insulating plate and slidably movable thereby in said plane into and out of engagement with said contact portion, said contactor being restrained by said plate against substantial transverse movement relatively thereto, said metal member having a perforated end portion projecting downwardly from the lower surface of said base to provide for attachment of a terminal wire, and a second one-piece combined contact and wiring terminal member having a resilient contact portion positioned above and biased toward said contact portion first men tioned.

3. In an electric switch of the snap make and break: type for radio rheostats and the like, in combination, an insulating base having a relatively s mml substantially rectangular opening formed therein, a one-piece, fiat, punched sheet metal contact and terminal member positioned edgewis e within said opening, said metal memher having shoulders formed thereon for respectively engaging the upper and lower surfaces of said base, the shoulders engaging the upper surface of said base being upset edgewise after insertion of said metal member into said opening whereby said metal member is rigidly and permanently attached to said base, said metal memberhaving a punched upper edge forming a contact portion located in a plane substantially ilush with the upper surface of said base, a punched insulating plate movable transversely with respect to said base, a contactor loosely carried by said insulating plate and slidably movable thereby in said plane into and out of engagement with said contact portion, said contactor being restrained by said plate against substantial transverse movement relatively thereto, said metal member having an integral portion projecting downwardly from the lower surface of said base, said last mentioned portion having an opening formed therein to facilitate attachment of a terminal and a second one-piece combined contact and wiring terminal member having a resilient contact portion positioned above and biased toward said contact portion first mentioned.

4. In an electric snap switch, in combination,

an insulating base having a relatively small substantially rectangular opening formed therein, a one-piece, fiat, punched sheet metal member positionededgewlse within said opening, said member having shoulders iormed thereon within the plane thereof for respectively engaging the upper and lower surfaces of said base, certain of said shoulders being upset edgewise after insertion of said member into said opening whereby said member is rigidly and permanently attached to said base, said member having a punched upper edge forming a contact portion located in a plane substantially flush with the upper surface of said base, said member having an integral portion projecting downwardly from the lower surface of said base, said last mentioned portion having an opening formed therein to facilitate, attachment of a terminal wire, a second one-piece combined contact and wiring terminal member having a contact portion positioned above and resiliently biased toward said contact edge portion aforementioned, a, flat punched plate of insulating material continuously interposed between said contact portion and said contact edge portion, said plate having an opening formed therein, and a hemispherical headed contactor the head portion of which is interposed between said plate and said base and the substantially cylindrical shank portion of which is loosely positioned within said plate opening, to provide for sliding movement of said contactor into and out of bridging engagement with said, contact portions.

5. A combined radio rheostat and switch comprising, in combination, a one-piece inverted cupshaped metal casing, said casing having a, centrally located circular opening in the upper end wall thereof, a rheostat base and a switch base 7 consisting of a. pair of molded insulating members of cylindrical form and of substantially identical peripheral dimensions, both inserted upwardly in sequence into said. one-piece casing and interlocked with the latter against rotation with respect thereto, an operating shaft carried by said rheostat base and projecting beyond said casing through said opening in the upper end wall of the latter, a snap switch mechanism carried by said switch base and having an operative connection with said operating shaft, said casing having a plurality of spaced lugs formed integrally therewith and bent inwardly over the lower surface of said switch base to retain said parts in assembled relation, said snap switch mechanism including a plurality of one-piece combined contact and wiring terminal members the wiring terminal portions of which penetrate said switch base and are exposed at the lower surface ofthe latter, and said lugs being so arranged as to provide ample electrical cleanance between the same and said wiring terminal members.

6. In a. snap switch mechanism of thecharacter described, in combination, an insulating base, a fiat insulating plate pivotally supported for oscillatory movement in a plane parallel to said ham, said plate having an opening formed therein adjacent to the free end thereof, a bridging contactor having a cylindrical shank portion freely insertable upwardly through and loosely positioned within said plate opening, the upper end of said shank portion being substantially hemispherical and the same extending a substantial distance above the upper surface of said plate, said contactor having a substantially hemispherical head portion interposed between said plate and said base, a pair of alined sheet metal contacts secured to said base and respectively positioned above and below said plate, the lower contact having an edge portion thereof located in a plane. substantially flush with the surface of said me for engagement by said contactor head, the'upper contact being resilient base, said base having a relatively small substantially rectangular opening formed therein, a rigid one-piece, flat punched sheet metal contact and terminal member positioned edgewise within said opening, said member having shoulders formed at one end thereof and engaged with one ,surface of said base, said end being adapted to provide a contact surface, said member also having a pair of lugs formed integrally therewith accuses and bent edgewise into engagement with the other surface of said base,'whereby said member is rigidly and permanently attached to said base, said member having an integral end portion projecting downwardly from the lower surface tact portion, said contactor being restrained by said insulating member against substantial transverse movement relatively to the latter, and means including a coiled, over-the-center spring .for eiiecting such movements of said insulating member and said contactor with a snap action.

8. In an electric snap switch for radio rheostats and the like, in combination, an insulating base, said base having a relatively small substantially rectangular opening formed therein, a one-piece combined contact and wiring.

terminal member consisting of a fiat, substantially rigid sheet metal punching,- the terminal shank of said member being insertable downwardly into said opening and the contact head thereof having shoulders to limit said downward movement and to provide a contact surface exposed at the upper surface of said base, said terminal shank having integral lugs bent edgewise over the lower surface of said base to rigidly and permanently secure said member in posi-' tion, a second one piece, combined contact and wiring terminal member rigidly attached to said base and having a contact portion spaced from said contact surface first mentioned, an insulatingmember movable transversely of said base in a plane parallel to the latter, a contactor loosely carried by said insulating member and bodily movable thereby transversely of said base in opposite directions respectively into and, out of bridging engagement-with said contact sun face and said contact portion, said contactor being restrained by said insulating member against substantial transverse movement relatively to the latter, a punched and stamped sheet metal actuating element pivotally secured on said base, means including a coiled, over-the-'center spring interposed between said actuating element and said insulating member for efiecting snap movements of the latter from each extreme position thereof to the other, and an operating member having a lost-motion driving connection with said actuating element. I

9. In a snap switch mechanism of the char-- ing contactor having a cylindrical shank portion freely insertable upwardly through and loosely positioned within said plate opening, the upper end of said shank portion being substantially hemispherical and the same extending a substantial distance above the upper surface of said plate, said contactor having a substantially hemispherical head portion interposed between said plate and 'said base; a pair of alined metal contacts secured to said base and respectively positioned above and below said plate, the lower contact having a portion thereof located in a plane substantially'flush with the surface of said base for engagement by said contactor head, the upper contact being resilient and the same being formed to facilitate sliding engagement thereof by the shank end of said contactor, a pivotally supported sheet metal actuating member, and a spring interposedbetween said actuating memher and said plate.

GEORGE J. MEUER. 

